This procedure covers the removal and replacement of the AC condenser on a 2024 Rivian EDV 500 electric delivery van, including refrigerant recovery, front fascia removal, and system recharge.

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification
• AC line O-ring kit × 1 — Use OEM specification
• Receiver/drier × 1 — Replace when system is opened
• Front fascia clips × 1 — As needed for replacement
• R-1234yf refrigerant × 1 — Approximately 1.5-2.0 lbs
• PAG oil for R-1234yf systems × 1 — 50-75ml

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery using service disconnect located in rear cargo area
3. Allow AC system to equalize pressure for at least 30 minutes if recently operated
4. Verify refrigerant recovery equipment is certified for R-1234yf (not compatible with R-134a equipment)
5. Document refrigerant charge amount during recovery for proper refill
6. Place fender covers to protect painted surfaces during front fascia removal

Procedure

1. 1

   Recover refrigerant from AC system
   Connect R-1234yf recovery machine to service ports located in the engine bay. Follow machine manufacturer's instructions to fully recover refrigerant. Record the amount recovered for recharge reference. Wait at least 10 minutes after recovery to verify system holds vacuum, indicating no major leaks.
2. 2

   Remove front fascia lower section
   Remove plastic push clips securing the lower front fascia. Starting from the bottom center, carefully release the fascia clips working outward to each wheel well. Disconnect any fog light connectors if equipped. Support the fascia and remove mounting bolts at the upper edge. Carefully set aside the fascia on a protected surface.
3. 3

   Remove front grille assembly
   Remove the upper grille assembly by releasing the retention clips across the top edge. Disconnect any radar sensor connectors behind the grille. Note the routing of the charging port illumination wiring and carefully guide it through the grille opening. Remove grille and set aside.
4. 4

   Disconnect AC lines from condenser
   Locate the AC line connections at the condenser inlet and outlet on the passenger side. Use appropriate AC line disconnect tools to release the spring-lock couplings. Cap all open AC fittings immediately with plugs to prevent moisture entry and contamination. Inspect the O-rings on the lines for damage.
5. 5

   Remove condenser mounting hardware
   Remove the condenser mounting bolts securing the condenser to the radiator support brackets. There are typically four mounting points - two upper and two lower. Support the condenser while removing the final bolt to prevent it from falling.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
6. 6

   Extract condenser assembly
   Carefully tilt the top of the condenser toward the engine bay and lift upward to clear the lower mounting tabs. Guide the condenser out through the front of the vehicle, being careful not to damage the radiator fins or high-voltage wiring harnesses. Inspect the mounting rubbers and brackets for wear.
7. 7

   Prepare new condenser for installation
   Remove shipping caps from the new condenser. Check that the correct amount of PAG oil (typically 50-75ml for R-1234yf systems) is added to the new condenser as specified by the manufacturer. Install new O-rings on all AC line connection points, lubricating them lightly with refrigerant oil.
8. 8

   Install new condenser
   Guide the new condenser into position through the front opening, aligning the lower mounting tabs first. Tilt the assembly into vertical position and align all mounting holes. Install condenser mounting bolts and tighten to specification in a cross-pattern to ensure even seating.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
9. 9

   Connect AC lines to condenser
   Remove protective caps from condenser fittings and AC lines. Install new O-rings on both the condenser side and line side connections, lubricating with refrigerant oil. Push the spring-lock couplings together until they click into place. Verify connections are secure by attempting to pull them apart. Tighten any threaded fittings to specification.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Replace receiver/drier
    Locate the receiver/drier assembly (typically mounted near the condenser on the passenger side). Disconnect the AC lines using the same procedure as step 4. Remove mounting bracket bolts and extract the old receiver/drier. Install the new receiver/drier with fresh O-rings, reconnect lines, and torque fittings to specification. Keep new receiver/drier capped until immediately before installation to minimize moisture exposure.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Reinstall front grille and fascia
    Reconnect any radar sensors and charging port illumination wiring. Position the grille assembly and secure with retention clips. Install the front fascia lower section, reconnecting fog lights if equipped. Secure all mounting bolts and push clips. Verify all panels are properly aligned and secured.
12. 12

    Evacuate and recharge AC system
    Connect vacuum pump to AC system service ports. Evacuate system to at least 29 inches of mercury (98 kPa) and hold for minimum 45 minutes to remove all moisture and air. If vacuum holds steady, proceed with recharge. Add the documented amount of R-1234yf refrigerant plus any additional oil that was lost with the old condenser. Use recovery machine's recharge function or charging cylinder with proper manifold gauges.
13. 13

    Reconnect 12V battery and clear codes
    Reconnect the 12V auxiliary battery in the rear cargo area. Using a compatible scan tool, clear any fault codes related to the AC system or refrigerant pressure sensors. Verify no new fault codes are present.

Reassembly

1. Ensure all AC line fittings are torqued to specification with new O-rings installed
2. Verify front fascia and grille are fully seated with all clips and fasteners secured
3. Confirm all electrical connectors for sensors, cameras, and lighting are properly reconnected
4. Double-check that no tools or parts have been left in the engine bay

Verification

• Start vehicle and activate AC system at maximum cooling setting
• Monitor AC system pressures using scan tool or manifold gauges - should show appropriate low side (25-45 PSI) and high side (200-300 PSI) pressures at idle in ambient conditions
• Verify cold air is flowing from cabin vents with temperature dropping below 45°F (7°C) at the center vents
• Inspect all AC line connections for signs of refrigerant leaks using electronic leak detector or UV dye/light
• Check for any unusual noises from the AC compressor or condenser fan operation
• Verify all warning lights and fault codes remain clear after 10 minutes of AC operation
• Perform a visual inspection of the front fascia alignment and verify all lighting functions work properly

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